Durable Corrosion Protection of Chloride

Contaminated Concrete Structures with

MC-KKS/B

Exclusive Cooperation

• Introduction to the causes of the corrosion of the

concrete reinforcement and structure of the protection

system

• Application of

• Step-by-step explanation of the system‘s application

• Development of the system

• Areas of application and reference buildings

• Synopsis

Outline

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Causes for corrosion of concrete steel in

reinforced concrete

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Problem? Yes!!!

Steel corrosion

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Steel corrosion

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Solution 1: Principle W (Rili-SIB)

Steel corrosion

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Solution 2: Principle W plus (freely adapted from Rili-SIB)

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Steel corrosion

Solution 3: Principle K (Rili-SIB)

Ship sacrificial anodes

MC-KKS/B

Sir Humphry Davy

Concrete surface Connection

Cathodic corrosion protection with zinc

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reinforcement (cathode) concrete

Blasted concrete

surface

Blasted connection

Cathodic corrosion protection with zinc

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reinforcement (cathode) concrete

Zinc layer (anode)

Cathodic corrosion protection with zinc

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reinforcement (cathode) concrete

Top coating

Cathodic corrosion protection with zinc

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reinforcement (cathode) concrete

Comparison: alkaline battery (voltage 1,5 V)

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Monitoring

Cathodic corrosion protection with zinc

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Deckschicht

Time saving Cost saving

Maintenance-free No reduction of

headroom and bearing

load

MC-KKS/B

Maintenance concept (qualified planner)

Assessment of the actual state:

chloride analysis, potentials,…

+

Metal conductive through connection of the reinforcement

Confirmation of the applicability of

Application

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• Rehabilitation of cracks, hollow areas and

loose concrete areas

• Repair work on damaged steel

reinforcement

• Filling and reprofiling

Selective refinishing of damaged spots

Application

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Cemented and blasted connection

Welding of the connection

bolt

Insertion of connections

Application

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Shot blasting

Surface treatment

Application

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Automated application

Application of the zinc anode

Application

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Manual application

Application of the zinc anode

Application

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Description of the thermal spraying process

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Description of the thermal spraying process

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- Flame spraying process since 1909

- Arc spraying process since 1911

- Since then mainly applied for the corrosion protection of steel

- Since the 1970s applied for reinforced concrete

Tensile bond test of zinc on concrete

MC-KKS/B

Monitoring box

Monitoring field

Reference electrode

Monitoring

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Test field in Helgoland

Test field in Duisburg

Online monitoring

Development of the system

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Development of the system Outdoor exposure Helgoland

Environmental conditions Helgoland

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Environmental conditions

Helgoland

http://blog.bild-in-sicht.de/wp-content/uploads/2012/01/helgoland-sturm1.jpg

http://www.kuestenforum.de/showthread.php?t=2660

Development of the system

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Outdoor exposure Helgoland

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Outdoor exposure Helgoland

Development of the system

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Unprotected sample (after

13 years)

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Development of the system

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Outdoor exposure Helgoland

Protected sample (after 13 years)

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Development of the system

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Structure of the samples

- CEM III/A 42,5

- 0 %, 1 % et 3 % chloride portion

- fly ash admixture

+ carbonated up to the reinforcement

=> high electric resistivity

- with and without zinc layer

(d = 250 µm)

Development of the system

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Development of the system

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Development of the system

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Current 0.1 mA/m² 1.0 mA/m² 2.0 mA/m² 5.0 mA/m²

Duration > 1000 years > 100 years 53 years 18 years

Assumption: 1,2 kg Zn/m²; charge: 780 Ah/kg Zn

Durability of galvanic anodes

=> Theoretical durability: more than 50 years!!!

780 Ah/kg x 1,2 kg/m² = 936 Ah/m²

Protective current: 2 mA/m²

936.000 mAh/m² / 2 mA/m² = 468.000 h

Development of the system

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Previously: manual floor application

Today: automated floor application: - Car parks in Erlangen (6500 m²), Frankfurt (two

test fields of 150 m² each), Schweinfurt (2500 m²), Blaubeuren (1500 m²), Hanover (2000 m²), Ludwigshafen (700 m²), Bielefeld (1000 m²)

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International standard

Development of the system

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- Cooperation with MC-Bauchemie

- Tests of various coating systems carried out

on real structures

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Development of the system

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Successful independent assessments

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Development of the system

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(Source: Documentation Dr. Reul, Ingenieurbüro für Bauchemie, Illertissen)

Car park Blaubeuren (1500 m²)

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Development of the system

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(Source: Documentation Dr. Reul, Ingenieurbüro für Bauchemie, Illertissen)

„The average surface tensile strength amounts to

1.424 N/mm².“

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Development of the system

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(Source: Documentation Dr. Reul, Ingenieurbüro für Bauchemie, Illertissen)

„The average tensile bond strengths of the zinc layer before the

application of the primer amounted to 1.364 N/mm².“

MC-KKS/B

Development of the system

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„The primer leads to a significant increase of the surface bonding strength,

i.e. the surface quality of the concrete in the system of concrete/zinc/resin

was enhanced by in part more than 100 %,…“

(Source: Documentation Dr. Reul, Ingenieurbüro für Bauchemie, Illertissen)

MC-KKS/B

Red:

special primer

Development of the system

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Car park Blaubeuren (1500 m²)

Test field Date 100-mV Criterion Current Temperature

1 (car park

middle)

30.08.12 fulfilled after 45 min 56.3 mA 16.0 °C

2 (car park

end)

25.10.12 fulfilled after 50 min 36.5 mA 9.0 °C

MC-KKS/B

• Car parks

• Bridges and industrial constructions

• Offshore structures (dolphins, shipyards, dry docks, etc.)

• Foundations

Typical areas of application of the system

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Reference buildings

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Hoechst Industrial Park (compressor platform and stair tower)

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Reference buildings

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Bridge Wimereux (F)

Car park

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Reference buildings

• Reinforced concrete dolphins in Bahrain

• Car park in Schwäbisch-Hall

• Car park of the university RWTH Aachen

• Water tower in Luxemburg

• 2 industrial buildings in Hoechst Industrial Park

• Bridge over the Emscher in Dinslaken

• SNCF bridge in Wimereux (F)

• Building facade in Biarritz (F)

• Car park in Frankfurt

• Car park in Erlangen

• Bridge of a chemicals plant in Wesseling

• Car park in Schweinfurt

• Car park in Saas-Fee (CH)

• Car park in Blaubeuren

• Harbour area in Nice (F)

• Car park in Hanover

• Car park in Tettnang

• Car park in Bielefeld

• Car park in Munich

• Car park in Sindelfingen and Böblingen

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Synopsis

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• Short duration of the rehabilitation works =>

high time saving compared to other repair

systems

• High cost saving thanks to the short duration

of the rehabilitation works and the absence

of drilling and demolition works

• Maintenance-free performance of the

system => fewer errors, no high follow-up

costs, no external electrical components

• No reduction of the headroom and the static

load capacity

• Durability of the anode at least 30 years

Bottleneck

ramp

Bottleneck

access

MC-KKS/B

Thank you very much for

your attention

Dipl.-Ing. Markus Kattannek; Grillo-Werke AG; E-Mail: m.kattannek@grillo.de

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